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Tool Maintenance for Safety

A tool in poor repair is a hazard waiting for a busy day. Regular inspection and service keep tools predictable, which is what makes them safe.

Why does maintenance affect safety?

Loose heads, cracked handles, worn cords, missing guards and dull blades all lead to injuries. A hammer head that flies off, a wrench that slips or a grinder that kicks back is often a maintenance problem in disguise. Most failures give warning signs first.

Maintaining tools also saves money, because tools last longer and work better. The manual that came with each tool is the best guide to what to check and how often, and many can be found on the maker's website.

Tools that have been borrowed, dropped, left in the weather or used for jobs they were not made for deserve extra attention. If you cannot tell what happened to a tool, inspect it as if it were damaged.

How do I inspect hand tools?

Look at each tool before use. Check wooden handles for splits, loose heads and rough spots, and metal tools for cracks, mushroomed ends, bent shanks and worn jaws. Replace damaged tools instead of repairing them with tape or wire.

Keep cutting tools sharp and protect their edges. Use each tool for its intended purpose only. Do not use a wrench as a hammer or a screwdriver as a pry bar.

Keep handles dry and free of oil and grease so they do not slip. A tool that slides out of a greasy hand is as dangerous as one with a cracked head.

• Handles tight, smooth and uncracked.
• Heads firmly attached and not chipped.
• Jaws and teeth in good condition.
• Edges clean, sharp and covered when stored.

How do I inspect power tools?

Check cords, plugs, switches, guards and housings. Make sure guards are in place and work properly. Listen for unusual noises and note any vibration, heat or sparking. Take any tool with a problem out of service and tag it so no one else uses it.

Follow the manual for lubrication, cleaning and replacing parts such as brushes and belts. Use only the accessories the manufacturer approves, since the wrong blade or wheel can break or fly apart.

Check that the guards, shields and safety switches that came with a tool are still in place and working. Removing them to save time is a common cause of serious injury, and replacement parts are available from the maker.

What about air, battery and fuel tools?

Compressed air tools need hoses and fittings in good condition and attached firmly, and pressure settings come from the manual and the tool's rating. Do not use an air hose to clean clothing or skin. Battery tools need the right charger and undamaged packs, as covered in our battery article.

Gas-powered tools need fuel handling care and the correct fuel mix. Let engines cool before refueling and follow the owner's manual for service.

Check the compressor, hoses and regulators on a regular schedule, and drain moisture as the manual directs. Keep fuel cans and starting fluids away from hot engines and sparks.

How should tools be stored?

Store tools clean, dry and in a place where they are not damaged by other items. Racks, boards and cabinets keep edges apart and make missing tools obvious. Keep heavy tools low and light tools high, and keep sharp tools covered.

Moisture rusts metal and ruins electrical tools, so keep them out of damp areas. Return every tool to its place after use.

Do not hang heavy tools from cords or hoses, and keep power tools unplugged or with batteries removed when stored, especially where children could reach them.

What makes a good tag-out habit?

When a tool is found damaged, remove it from use and attach a clear tag that says what is wrong and who tagged it. The tag should not be removed until the repair is checked. This simple habit prevents someone else from picking up a faulty tool in a hurry.

Keep a repair or discard list so that tagged tools are not forgotten on a shelf.

Teach everyone, including teens, that reporting a damaged tool is a good thing. Make sure there is no penalty, and thank the person who speaks up.

Who should do repairs?

Simple tasks such as replacing a handle or brush are fine if the manual allows. Anything involving electrical components, safety guards or pressure parts should go to a qualified repair shop. Be honest about the limits of your skill.

Keep receipts and notes on repairs so that you know a tool's history.

Parts and manuals for older tools can often be found online or from the maker. If a tool cannot be repaired safely, retire it, even if it was a favorite.

Last reviewed: November 12, 2026. Written by the Farm Safety Editorial Team. See our editorial policy.